Collaborative R&D

The fixed annual contributions of ACOP Industry Partners fund a set of Collaborative R&D Projects, maximizing synergies and pre-competitive benefits. These projects, defined and conducted annually, integrate all partners' specific needs and ensure broad participation. They address both targeted improvements in individual manufacturing processes and overarching advancements in the entire production chain, including digitalization.

Project selection follows the ACOP Roadmap and is decided collectively at the Annual R&D Meeting. This roadmap, continuously updated for mid-term planning, remains proprietary.

Beyond the annual project selection, ACOP actively identifies funding opportunities for strategic topics that exceed the collaborative budget. To maintain independence and flexibility, ACOP can form dedicated sub-consortia for specific funding initiatives, complementing its Partner Community.

In five focus groups, we work on the collaborative research projects that we have agreed upon with the ACOP partners. The focus groups cover the process chain of optics production and deal with the following topics:

• Glass optics
• Plastic optics
  
• Metrology
• Assembly
• Digitalization
  

In what ways can GenAI be used to optimize the whole optics process chain?

Challenge and Motivation

• Generative AI (GenAI) models can produce text, images, videos, or other forms of data.
• In other domains, tools with pre-trained models such as Chat-GPT are already used for different use cases.

Objective

Creation of a use case landscape of applications of GenAI to optimize the optics process chain from simulation and design to manufacturing and metrology

Scope

• Identification of possible GenAI use cases along all stages of optics process chain
• Detailed characterization of use cases incl. benefits and challenges
• Implementation guideline for most relevant use cases

How can the curing behavior of bonding agent be analyzed using FEM simulation techniques?

Challenge and Motivation

• Bonding agents applied during assembly cause residual stresses on the optical surfaces.
• Relevant material characteristics and simulation approaches are unknown.

Objective

Build an FEM model for the numerical simulation of curing behavior

Scope

• Develop numerical expression from analytical model for selected bonding agent
• Measurement for shrinkage and measurement for elasticity for one parameter set
• Parameter study investigating the most influencing material properties through FEM simulation
• Search for suitable funding calls

What advantages does CVD-SiC offer compared to standardized WC molding tool material?

Challenge and Motivation

• Alternative to tungsten carbide materials for molding tools on the market.
• SiC deposited as a CVD layer shows promising properties for use as a molding material for glass molding applications.

Objective

Evaluation of the feasibility of using CVD-SiC materials as molding tools in glass molding production

Scope

• Advantages, limitations and mechanical properties of CVD-SiC molding tools according to literature
• In depth knowledge of CVD-SiC materials as molding tools in glass molding production

What leads to earlier failure of glass molding tools?

Challenge and Motivation

• The lifetime of ta-C coatings applied on glass molding tools highly depends on the glass materials chemical composition.
• The molding of certain glasses can lead to early deterioration or delamination of the coating on the surface of the mold.

Objective

Analysis of glass-dependent degradation mechanisms of ta-C coated molding tools

Scope

• Research on glass-dependent degradation of molding tools.
• Database on coating behavior based on molded glass. Built based on previous experience from our partners
• Determination of the relationship between the chemical composition of the glass and the early degradation of the ta-C coating in molding tools

How can metrology be integrated into the production of optical microstructures to optimize and better understand their performance?

Challenge and Motivation

Quality control of optical surfaces and their molds is necessary to understand and optimize their performance

Objective

Development of a method for the metrological characterization of optical surfaces along the process chain, from design to mold insertion, through the replicated article and back to design

Scope

• Definition of specific use case, identifying suitable metrological systems
• Development of a method to optimize process chain
• Optional: Conducting test measurements for validation of method

Can the impact of external/internal structural variations on lens optical performance be simulated/quantified?

Challenge and Motivation

The presence of periodic structures and refractive index inhomogeneities can have a direct impact on the optical performance of molded lenses

Objective

Determine the correlation between defined variations and the reduction of optical performance below a critical threshold for specific applications

Scope

• Optical simulation of mold lenses with  induced internal/external structural variations like:
  • refractive index inhomogeneities
  • periodic structures
• Correlation between the presence of these structural variations and the optical performance of the lenses

How do protective coatings affect clogging of mold microstructures during plastic injection molding process?

Challenge and Motivation

• Microstructures in molds tend to get clogged during plastic injection molding process.
• Clogged microstructures result in poor replication quality in following cycles.
• Cleaning of microstructures is cumbersome.

Objective

Comparison of different protective coatings and their effects on clogging tendency of microstructured molds

Scope

• Determination of suitable coating solution for plastic injection molding
• Mold of challenging plastic material  and comparison of process improvements
• Investigation of interdependency of process parameters and materials and their effects on clogging tendency

2024

How does decoating and recoating of protective layers impact the surface quality of molding tools?

Challenge and Motivation

• After molding cycles or coating degradation, the protective layer is decoated from the mold.
• The molding tools are recoated for optics production.
• The influence of decoating on the tools is uncertain.

Objective

Determine the influence of decoating in the molding tool and its influence.

Which protective coatings reduce the demolding force of injection molding tools?

Challenge and Motivation

• Utilizing tool coatings in replicative optics manufacturing can significantly enhance the lifespan of molding tools.
• The application of coatings on the contact surface can reduce material adhesion and effectively minimize demolding force.

Objective

Determination of a suitable protective coating for plastic injection molds.

What are available in-process or in-line measurement alternatives for Glass Molding?

Challenge and Motivation

• Precision glass molding is conducted at elevated temperatures in a closed chamber.
• Sensors are installed to monitor and determine relevant process information.

Objective

Research and evaluation of in-process in-line measurement alternatives for Glass Molding.

Can the 3D shape of large free-form optical components be measured optically, automatically and rapidly?

Challenge and Motivation

• High-precision manufacturing and assembly is only possible when supported by efficient and accurate metrological methods
• Fast and precise measurement of large free form optics is a very challenging process

Objective

Research on possible inline metrological solutions for the fast and precise measurement of large free form optics

Can the surface of optics of different sizes and materials be inspected in an automated way?

Challenge and Motivation

• Accurate detection of lens defects, such as scratches, digs or black spots, is very important in the optics industry
• The standard methods for surface inspection relies on manual-visual analysis, which introduces subjectivity into the analysis process

Objective

Research on existing methods and conceptualization of an automated system for surface inspection of optics

What are the available solutions for proper handling of micro-lenses?

Challenge and Motivation

• Miniaturization trend leads to smaller lenses.
• For different stages of the production the lenses must be handled properly.
• A flexible and affordable solution is preferred with the intent of adoption for different optical designs.

Objective

Assessment of handling technologies for micro-lenses.

Can 3D glass printing enhance optics?

Challenge and Motivation

• Structures with the freedom of 3D printing would allow for advanced functionalized surfaces like phase masks on top of lenses
• The characterization and applications are unclear: What are the limitations in geometry? How can surface treatments be applied?

Objective

Define and address applications of 3D glass printing

Which parameters are required to build up an FEM simulation model?

Challenge and Motivation

• Bonding agents applied during assembly cause residual stresses on the optical surface
  

Objective

Perform study to define the material modeling parameters required for an FEM simulation model

2023

What factors influence wear on ta-C coated PGM molding tools?

Challenge and Motivation

• The lifetime of ta-C coating applied on PGM molding tools depends essentially on:
  • Mold material and coating process
  • Type of the molded glass
  • Parameters of molding process

Objective

Development of methods for the wear analysis of coated molding tools and determination of the influencing factors

How can the bonding agent behavior in an optical system be predicted?

Challenge and Motivation

• Bonding agents applied during assembly cause residual stresses on the optical surface
• Cements and adhesives may lead to deviations of the desired optical properties (shrinkage, refractive index and wavefront variations)

Objective

Determine the feasibility and establish the principles for the development of a FEM simulation model for optical systems (doublets, triplets) through literature research

Which alternative cleaning methods can improve the optics production process?

Challenge and Motivation

• Standard cleaning agents (acetone, isopropanol, and others) might not remove all impurities from glass and plastic optical
  components
• Adhesive substances used during the production process are difficult to remove

Objective

Identify and select suitable cleaning methods to be used in optic production processes

Is it possible to apply 3D printed molds in replicative optics manufacturing?

Challenge and Motivation

• The current manufacturing of molding tools for optics replication by UP processes is high in cost and time-consuming
• Additive manufacturing (AM) technologies are a promising solution for rapid prototyping and for addressing additional features

Objective

Research on the potential of AM and its application on both injection and glass molding

Can microlenses be accurately characterized with Shack-Hartmann wavefront sensors?

Challenge and Motivation

• The manufacture of high-quality microlenses is only possible if it is supported by efficient and accurate metrology
• To ensure the best performance of high-quality microlenses, it is necessary to have a method that evaluates the overall optical function

Objective

Measurement of microlenses with an SHWS-based test stand in transmission mode

Can double-sided aspheres be optically aligned on a centering grinding machine?

Challenge and Motivation

• High-quality aspheres manufacturing is only possible when supported by efficient and accurate metrology
• Alignment of aspheres in a center grinding machine is a very challenging process

Objective

Research on the development of a measurement technology concept for clamping and aligning aspheres in a center grinding machine

Can black specks on molded lenses be detected and their impact on their optical performance be determined?

Challenge and Motivation

• High-quality polymer lenses manufacturing is only possible when supported by efficient and accurate metrology
• The presence of "black specks" on injection molded polymer lenses can significantly decrease their performance

Objective

Determine which metrological methods can be used/adapted for fast and automated detection of black specks in molded lenses

How does a production tool for assembly look like?

Challenge and Motivation

• Moving from a prototypical test bench towards a production tool concept
• Interface identifications for maximized flexibility towards new applications with minimal changes in design

Objective

Concept of a production tool for the assembly process from P6 (2022)

2022

What benefit do DLC coatings bring to optics manufacturing?

Challenge and Motivation

• DLC coatings extend the lifetime of molding tools and can serve as protectivecoating
• When deposited on complex surfaces (e.g.highly curved) the coating’s inhomogeneity can influence their geometry, which effects the final shape

Objective

Research on the potential of the application of DLC coatings for molding tools

How can the centering inaccuracy of the two halves of the mold be reduced?

Challenge and Motivation

• High-precision micro-optics in particular require compliance with low tolerances for perfect function
• The offset of the two mold halves impairs the optical function
• The market demands sub-µm deviations

Objective

Validation of the results, found in the first ACOP project, considering the injection

What boundary parameters allow/limit the study of miniaturized lenses with OCT?

Challenge and Motivation

• Modern optical systems increasingly require the use of aspheric miniaturized lenses. Therefore, its precise characterization is crucial.
• High-speed centering and shape inspection are transcendental measurements in high-quality miniaturized lens characterization

Objective

Measurement of miniaturized lenses with Optical Coherence Tomography (OCT)

How can the transmission wavefront error (TWFE) of lenses be measured reliably?

Challenge and Motivation

• High-quality lens manufacturing is only possible when supported by efficient and accurate metrology
• To ensure the best performance for high quality optical systems it is necessary to have a method that evaluates the overall optical function

Objective

Measurement of lenses with a SHWS-based test stand in transmission mode

How can optics be efficiently aligned based on wavefront measurements?

Challenge and Motivation

• Precise alignment of optics in the beam path is needed for high assembly quality
• Evaluation of wavefront instead of intensity distribution, provides more detailed information about misalignments of optics
• Reducing waste with higher optics quality

Objective

Implementation of a function-oriented alignment via evaluation of the wavefront

How can the quality of a lens be predicted by using production and simulation data?

Challenge and Motivation

• Data is collected along the process chain of glass and plastics molding
• The collected data is often not connected and therefore not suitable  for analysis
• The effort to measure lenses is often high and simulation and production data is not used

Objective

Development of a data platform providing predictive quality as a service

2021

How is the calculation of optical properties of molded lens conducted and validated?

Challenge and Motivation

• Residual stress in molded lens
• Photoelasticity of lens material leads to local and direction dependent refractive index
• Birefringence and inhomogeneity exist at the same time

Objective

Calculation of optical properties of molded lens and data integration into digital-twin

How to reduce the centering inaccuracy of the two halves of the mold?

Challenge and Motivation

• High-precision micro-optics in particular require compliance with low tolerances for perfect function
• The offset of the two mold halves impairs the optical function
• The market demands sub-µm deviations

Objective

Validation of existing centering concepts and arrangements

How can micro optical lenses be measured reliably?

Challenge and Motivation

• Modern optical designs often require aspheric microlenses to reduce the size and improve the performance of optical systems
• Manufacturing of aspheric microlenses is a challenge and requires knowledge of metrological possibilities

Objective

Measurement of microlenses with different metrology systems/technologies

How can the level of automation be increased?

Challenge and Motivation

• Product development goes in parallel with automation development
• Assembly cells must allow easy integration and configuration of new technologies (e.g. AI process)
• Automation not yet designed for this

Objective

Demonstration of IPT software and hardware tools on the basis of a concrete process example

Which cross-company digitalization issues can be solved by ACOP activities?

Challenge and Motivation

In many company, digitalization is seen as mandatory in the future but the obstacle to start the digital transformation are high, due to the fact that the point to start is unknown and the there is no strategy to follow.

Objective

Identifying and develop the digitalization strategy and align emerging questions with ACOP activities